TECHNOLOGY – Turbonik

The Micro Steam Turbines from TURBONIK

PUSHING THE BOUNDARIES FOR TOMORROW'S ENERGY

Turbine technology rethought and implemented

Steam turbines are one of the oldest and most proven technologies for generating electricity. Since their invention at the end of the 19th century, they have been the foundation of power generation in power plants and large industrial facilities. However, in times of energy transition, decentralized power generation is playing an increasingly important role. The focus is on local generation and optimal use of existing energy resources.

That is why we have taken steam turbine technology and developed it to meet the needs of the 21st century. We have focused on users who already use steam in their processes, but whose steam volumes and properties are not sufficient to operate conventional steam turbines.

With the requirements of these users in mind, we have focused on developing a technology that makes steam turbines available as a simple efficiency measure in companies that use steam. We rethought and implemented three key aspects of steam turbine technology.

UP TO 50.000 RPM

The impeller and generator are directly coupled without a gearbox. As a result, they operate at the world's highest speeds for steam turbines

FOR SATURATED STEAM

Micro Steam Turbines are specifically designed for use with standard industrial saturated steam boilers

WATER LUBRICATION

Turbonik turbines use water as a lubricant for the bearings, making them 100% oil-free.

HIGHEST SPEED AND EFFICIENCY IN POWER GENERATION

The focus is on maximum efficiency and performance. The turbines are designed so that the turbine impeller and the generator are directly coupled without a gearbox. As a result, they operate at speeds of up to 50,000 rpm, the highest in the world for steam turbines. A frequency converter then converts the power generated to the mains frequency (50 Hertz, 400 Volt). As a result, our single-stage micro steam turbines achieve an isentropic turbine efficiency that is 40% higher than comparable conventional steam turbines in this power range. This means that the fuel used to generate steam is used as efficiently as possible. At full load and in continuous operation at 600 kW, a Turbonik turbine can generate approximately 5 GWh of electricity per year, which is equivalent to the annual consumption of approximately 1,000 four-person households.

SMALLEST FOOTPRINT AND MINIMAL USE OF MATERIALS

Another advantage of Turbonik’s micro steam turbines is their small footprint. In many companies, steam boiler systems have historically grown and additional space for new installations is limited. Speed has an extremely positive effect on the size of the turbine runner and turbine housing. With a runner diameter of only about 20 cm and a compact design that fits within the dimensions of a euro-pallet including the generator, Turbonik turbines are extremely space efficient.

The total weight of the mechanical components is only about 1000 kg, which means that they can be installed on almost any industrial floor. For many companies, the micro steam turbine is the first opportunity to use steam turbines as an efficient technology. The control cabinets can also be set up separately from the turbine, providing additional flexibility for integration and connection.

100% OIL-FREE THANKS TO INNOVATIVE WATER LUBRICATION

Another important aspect for us is environmental friendliness. Turbonik turbines are completely oil-free; for the first time, water is used as a lubricant in steam turbines instead of oil. Especially in the food industry, product safety and cleanliness are key criteria for efficiency measures in plant engineering. The bearing system was developed by Turbonik and is based on operating experience with bearings in high-speed ORC turbines.

A special feature of the water lubrication system is that part of the expanded steam is condensed even during turbine operation, thus continuously refilling the water circuit. An automatic level control prevents overflow. The water circuit can be cooled either by a recooler (air) or by direct connection of a heat exchanger to a factory cooling water network.

Our managing director Dr. Bülten presents the technology of the turbines.

USE OF THE TURBINE

A prerequisite for using a micro steam turbine in your operation is the presence of a pressure differential between the steam generator and the consumer or within a steam network. As a guideline, the pressure ratio between turbine inlet and outlet pressure should be greater than 2, and the steam mass flow should be greater than 1.2 tons per hour. For larger volumes of steam, lower pressure ratios may be economically feasible.

We will then custom calculate the electrical output based on your specifications. You can make a preliminary estimate of electrical power for your application here.